Hydraulic tank
Hydraulic reservoir monitoring records fill level, tank temperature and return-line temperature in a hydraulic power unit. If the hydraulic tank's oil drops or gets too warm, maintenance is alerted immediately, before the unit runs dry or shuts down.
Hydraulic tank at a glance
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Hydraulic reservoir monitoring: level and temperature
In the solution example, ifm's moneo software records the readings via an edge device. Existing level sensors are integrated or newly fitted to the tanks, joined by a vibration sensor and an inductive sensor on the pump and pressure sensors that measure differential pressure across the hydraulic filter. Values reach moneo via IO-Link masters. Existing analogue sensors can be tapped via a Y-path retrofit. moneo outputs the data via MQTT or OPC UA and forwards warnings through its SFI interface directly to SAP PM or sends them by email.
The example comes from metal and electronics, with condition monitoring and level measurement as use cases. ifm uses it to monitor the hydraulic power units of test rigs, such as an impulse pressure test rig that puts pressure sensors through accelerated life testing. Return-line temperature is critical: above 62 degrees, the unit shuts down and the whole system fails. moneo therefore also records the temperature difference between tank contents and return line. When needed, the system orders the required spare parts automatically, and filters are cleaned at the right time rather than on a fixed cycle.
Hydraulic reservoir monitoring: frequently asked questions
Why monitor hydraulic tank temperature?
Temperature shows whether the hydraulic power unit is operating within its permitted range. In ifm's solution example, moneo records tank temperature, return-line temperature and the difference between them. If return-line temperature exceeds 62 degrees, the unit shuts down and the entire system fails. An alarm on deviations gives maintenance time to step in beforehand.
How does hydraulic oil level monitoring work?
Fill level is measured by level sensors on the tank, which are either already installed and integrated or newly fitted. In ifm's example, their readings reach the moneo software via IO-Link masters. If the hydraulic oil in the tank drops, the maintenance technician receives an email or a notification in SAP PM. This matters because a hydraulic power unit must never run dry.
Why monitor the hydraulic tank return line?
Return-line temperature is an important limit for operating a hydraulic power unit. In the solution example, if it exceeds 62 degrees, the unit shuts down and the entire system fails. moneo therefore monitors return-line temperature continuously and compares it with the temperature of the tank contents. Automated alarm management reports deviations immediately and enables a preventive response.
What does hydraulic filter differential pressure indicate?
Differential pressure shows how contaminated the hydraulic filter is. Because dirt ingress into a hydraulic system can hardly be prevented, filters must be cleaned or replaced regularly. In ifm's example, pressure sensors measure the differential pressure and send it to moneo. Cleaning then takes place at the right time, and cyclical checks are no longer necessary.
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